Heater for an aerosol delivery device and methods of formation thereof

ABSTRACT

The present disclosure relates to aerosol delivery devices, methods of forming such devices, and elements of such devices. In some embodiments, the present disclosure provides a heating member that can be formed of a heating element conformed to a heater substrate configured as a truncated cone (or similar shape) having a first end of a first size and a second end of greater size. In some embodiments, the disclosure provides methods of forming an aerosol delivery device, which can include providing a shell, providing a heating member formed of a heating element conformed to a substrate, configuring the heating member as a truncated cone (or similar shape) having a first end of a first size and a second end of greater size, and inserting the heating member within the shell.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 16/050,598,filed on Jul. 31, 2018, which is a division of U.S. application Ser. No.14/329,334, filed on Jul. 11, 2014, each of which is incorporated byreference herein in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices such assmoking articles, and more particularly to aerosol delivery devices thatmay utilize electrically generated heat for the production of aerosol(e.g., smoking articles commonly referred to as electronic cigarettes).The smoking articles may be configured to heat an aerosol precursor,which may incorporate materials that may be made or derived from tobaccoor otherwise incorporate tobacco, the precursor being capable of formingan inhalable substance for human consumption.

BACKGROUND

Many smoking devices have been proposed through the years asimprovements upon, or alternatives to, smoking products that requirecombusting tobacco for use. Many of those devices purportedly have beendesigned to provide the sensations associated with cigarette, cigar, orpipe smoking, but without delivering considerable quantities ofincomplete combustion and pyrolysis products that result from theburning of tobacco. To this end, there have been proposed numeroussmoking products, flavor generators, and medicinal inhalers that utilizeelectrical energy to vaporize or heat a volatile material, or attempt toprovide the sensations of cigarette, cigar, or pipe smoking withoutburning tobacco to a significant degree. See, for example, the variousalternative smoking articles, aerosol delivery devices, and heatgenerating sources set forth in the background art described in U.S.Pat. No. 7,726,320 to Robinson et al., U.S. Pat. Pub. No. 2013/0255702to Griffith Jr. et al., and U.S. patent application Ser. No. 13/647,000to Sears et al., filed Oct. 8, 2012, which are incorporated herein byreference in their entirety. See also, for example, the various types ofsmoking articles, aerosol delivery devices, and electrically poweredheat generating sources referenced by brand name and commercial sourcein U.S. patent application Ser. No. 14/170,838 to Bless et al., filedFeb. 3, 2014, which is incorporated herein by reference in its entirety.

It would be desirable to provide a reservoir for an aerosol precursorcomposition for use in an aerosol delivery device, the reservoir beingprovided so as to improve formation of the aerosol delivery device. Itwould also be desirable to provide aerosol delivery devices that areprepared utilizing such reservoirs.

SUMMARY OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices, methods offorming such devices, and elements of such devices. In some embodiments,the present disclosure provides heaters, heating elements, or the likethat may be suitable for use in an aerosol delivery device. For example,in some embodiments the present disclosure provides an aerosol deliverydevice comprising a heating member formed of a heating element conformedto a heater substrate configured as a truncated cone having a first endof a first size and a second end of greater size.

In various embodiments, the present aerosol delivery devices andelements suitable for use therein can be defined by one or more of thefollowing statements. Specifically, an aerosol delivery device asdescribed above may include one, two, or any number of the followingcharacteristics in any combination.

The heater substrate can comprise a film or membrane underlying theheating element.

The heater substrate can further comprise a film or membrane overlyingthe heating element (and all or part of the film or membrane underlyingthe heating element).

One or both of the heater substrate and the film or membrane overlyingthe heating member can comprise a textured surface. The texturing can beconfigured to provide for capillary flow across the textured surface.

The heating member can comprise an electrically conductive ink.

The aerosol delivery device can comprise a porous transport elementconfigured for passage of an aerosol precursor composition along alength thereof, the porous transport element having a first end in aheating arrangement with the heating member.

The truncated cone can include an interior passage therethrough, and thefirst end of the porous transport element in the heating arrangementwith the heating member can be positioned at least partially within theinterior passage of the truncated cone.

The first end of the porous transport element in the heating arrangementwith the heating member can be positioned so as to at least partiallysurround the first end of the truncated cone.

The porous transport element can be a fibrous mat.

The porous transport element can be formed of materials, such as carbonfiber, fiberglass, cotton, silk, and the like.

The porous transport element can be formed of natural materials,synthetic materials, combinations of natural and synthetic materials,blends of one or more material types, and blends of one or more fibertypes.

The fibrous mat can comprise a plurality of layers.

The fibrous mat can be pleated, can comprise one or more cutouts havingone or more different shapes, and can have shaped edges.

The first end of the fibrous mat can comprise fewer layers than theremainder of the fibrous mat.

The porous transport element can comprise central passage through thelength thereof.

The aerosol delivery device can comprise an airflow path entering thelesser sized first end of the truncated cone, passing through aninterior passage therethrough, and exiting past the greater sized secondend of the truncated cone.

The aerosol delivery device can comprise an airflow path exterior to theheating element passing around the truncated cone from the first endthereof past the greater sized second end thereof.

The heating member can be mounted inside a support frame.

The heater substrate can be configured as a frustum.

The heater substrate can be a multifaceted shape.

The porous transport element can comprise a support member passingcentrally longitudinally therethrough.

The support member can have an open first end and an open second end andcan include one or more passages therethrough.

The support member can comprise one or more air inlets formed in a wallthereof.

The support member can comprise one or more aerosol outlets formed in awall thereof.

The support member can comprise a flow diverter therein.

In some embodiments, an aerosol delivery device according to the presentdisclosure can comprise: a shell having an air inlet and a mouthpiececonfigured for exit of a formed aerosol; a heating member positionedwithin the shell and being formed of a heating element conformed to aheater substrate configured as a frustum with an interior passagetherethrough and having a first end of a first size and a second end ofgreater size; a porous transport element configured for passage of anaerosol precursor composition along a length thereof, the poroustransport element having a first end in a heating arrangement with theheating member; and an airflow path through the shell from the air inletto the mouthpiece past the first end of the frustum and then past thesecond, greater sized end of the frustum.

In further embodiments, the present disclosure can provide an atomizerthat can be included in an aerosol delivery device. An atomizer, forexample, can comprise a heating member formed of a heating elementconformed to a heater substrate configured as a truncated cone having afirst end of a first size and a second end of greater size. The heatingmember can be positioned within a support frame. The atomizer also cancomprise a porous transport element configured for passage of an aerosolprecursor composition along a length thereof, the porous transportelement having a first end in a heating arrangement with the heatingmember. The porous transport element can comprise a support memberpassing centrally longitudinally therethrough. The atomizer can beconfigured for insertion into a shell of an aerosol delivery device tobe in electrical connection with a power source directly or through oneor more electrical contacts, which contacts may comprise part of aconnector for connecting the shell to a second shell including a powersource.

In some embodiments, the present disclosure can provide methods forforming an aerosol delivery device. The methods can include combining aheating member with a shell of the delivery device, combining theheating member with a porous transport element and a shell, or formingthe heating member and the transport element into an atomizer, which canbe combined with a shell.

In certain embodiments, a method of forming an aerosol delivery devicecan comprise: providing a shell; providing a heating member formed of aheating element conformed to a substrate; configuring the heating memberas a truncated cone having a first end of a first size and a second endof greater size; and inserting the heating member within the shell.

In various embodiments, the present method for forming an aerosoldelivery device can be defined by one or more of the followingstatements. Specifically, such method as described above may includeone, two, or any number of the following characteristics in anycombination.

The method can comprise providing a porous transport element configuredfor passage of an aerosol precursor composition along a length thereof,the porous transport element having a first end and a second opposingend, and configuring the first end thereof in a heating arrangement withthe heating member.

The method can comprise contacting the second end of the poroustransport element with the aerosol precursor composition.

The truncated cone can include a central passage therethrough, andconfiguring the first end of the porous transport element in a heatingarrangement with the heating member can comprise inserting the first endof the porous transport element into the central passage at the second,greater sized end of the heating member.

The first end of the porous transport element can comprise a centralopening therein, and configuring the first end of the porous transportelement in a heating arrangement with the heating member can compriseinserting the first, lesser sized end of the heating member into thecentral opening in the first end of the porous transport element.

The heating member can be formed on the substrate by printing anelectrically conductive ink thereon.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 is a partially cut-away view of an aerosol delivery devicecomprising a cartridge and a control body including a variety ofelements that may be utilized in an aerosol delivery device according tovarious embodiments of the present disclosure;

FIG. 2 is a plan view of a heating member according to an exemplaryembodiment of the present disclosure comprising a heating elementconformed to a heater substrate;

FIG. 3 is a perspective view of a heating member according to anexemplary embodiment of the present disclosure, the heating membercomprising a heater substrate that is curved or folded to form atruncated cone;

FIG. 4 is a cross-section through line 4-4 of the heating memberillustrated in FIG. 2;

FIG. 5 is a cross-section of a heating member according to an exemplaryembodiment of the present disclosure showing a heating element layeredbetween a heater substrate in the form of a thin film and a heater coverin the form of a thin film;

FIG. 6 is a plan view of a porous transport element according to anexemplary embodiment of the present disclosure, the transport elementcomprising a first end formed of a single layer of a fibrous mat and asecond end formed of a plurality of layers of a fibrous mat;

FIG. 7 is a cross-section through line 7-7 of the porous transportelement illustrated in FIG. 6;

FIG. 8 is a partially cut-away view of an aerosol delivery deviceaccording to an exemplary embodiment of the present disclosure, thedevice comprising a heating member configured as a truncated cone and aporous transport element positioned with a first end interior to theheating member, both being configured within a shell;

FIG. 9 is a partially cut-away view of an aerosol delivery deviceaccording to an exemplary embodiment of the present disclosure, thedevice comprising a heating member configured as a truncated cone and aporous transport element positioned with a first end interior to theheating member, the transport element comprising a support member andthe heating member comprising a support frame, and all being configuredwithin a shell; and

FIG. 10 is a partially cut-away view of an aerosol delivery deviceaccording to an exemplary embodiment of the present disclosure, thedevice comprising porous transport element with a heating memberconfigured as a truncated cone positioned with a first end interior to afirst end of the transport element, both being configured within ashell.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural referents unless the context clearly dictates otherwise.

As described hereinafter, embodiments of the present disclosure relateto aerosol delivery systems. Aerosol delivery systems according to thepresent disclosure use electrical energy to heat a material (preferablywithout combusting the material to any significant degree) to form aninhalable substance; and components of such systems have the form ofarticles most preferably are sufficiently compact to be consideredhand-held devices. That is, use of components of preferred aerosoldelivery systems does not result in the production of smoke in the sensethat aerosol results principally from by-products of combustion orpyrolysis of tobacco, but rather, use of those preferred systems resultsin the production of vapors resulting from volatilization orvaporization of certain components incorporated therein. In preferredembodiments, components of aerosol delivery systems may be characterizedas electronic cigarettes, and those electronic cigarettes mostpreferably incorporate tobacco and/or components derived from tobacco,and hence deliver tobacco derived components in aerosol form.

Aerosol generating pieces of certain preferred aerosol delivery systemsmay provide many of the sensations (e.g., inhalation and exhalationrituals, types of tastes or flavors, organoleptic effects, physicalfeel, use rituals, visual cues such as those provided by visibleaerosol, and the like) of smoking a cigarette, cigar, or pipe that isemployed by lighting and burning tobacco (and hence inhaling tobaccosmoke), without any substantial degree of combustion of any componentthereof. For example, the user of an aerosol generating piece of thepresent disclosure can hold and use that piece much like a smokeremploys a traditional type of smoking article, draw on one end of thatpiece for inhalation of aerosol produced by that piece, take or drawpuffs at selected intervals of time, and the like.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases, and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

Aerosol delivery devices of the present disclosure generally include anumber of components provided within an outer body or shell, which maybe referred to as a housing. The overall design of the outer body orshell can vary, and the format or configuration of the outer body thatcan define the overall size and shape of the aerosol delivery device canvary. Typically, an elongated body resembling the shape of a cigaretteor cigar can be a formed from a single, unitary housing, or theelongated housing can be formed of two or more separable bodies. Forexample, an aerosol delivery device can comprise an elongated shell orbody that can be substantially tubular in shape and, as such, resemblethe shape of a conventional cigarette or cigar. In one embodiment, allof the components of the aerosol delivery device are contained withinone housing. Alternatively, an aerosol delivery device can comprise twoor more housings that are joined and are separable. For example, anaerosol delivery device can possess at one end a control body comprisinga housing containing one or more reusable components (e.g., arechargeable battery and various electronics for controlling theoperation of that article), and at the other end and removably attachedthereto an outer body or shell containing a disposable portion (e.g., adisposable flavor-containing cartridge).

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and ceasing power for heat generation, such asby controlling electrical current flow the power source to othercomponents of the article—e.g., a microcontroller or microprocessor), aheater or heat generation member (e.g., an electrical resistance heatingelement or other component, which alone or in combination with one ormore further elements may be commonly referred to as an “atomizer”), anaerosol precursor composition (e.g., commonly a liquid capable ofyielding an aerosol upon application of sufficient heat, such asingredients commonly referred to as “smoke juice,” “e-liquid” and“e-juice”), and a mouthend region or tip for allowing draw upon theaerosol delivery device for aerosol inhalation (e.g., a defined airflowpath through the article such that aerosol generated can be withdrawntherefrom upon draw).

More specific formats, configurations and arrangements of componentswithin the aerosol delivery systems of the present disclosure will beevident in light of the further disclosure provided hereinafter.Additionally, the selection and arrangement of various aerosol deliverysystem components can be appreciated upon consideration of thecommercially available electronic aerosol delivery devices, such asthose representative products referenced in background art section ofthe present disclosure.

In various embodiments, an aerosol delivery device can comprise areservoir configured to retain the aerosol precursor composition. Thereservoir particularly can be formed of a porous material (e.g., afibrous material) and thus may be referred to as a porous substrate(e.g., a fibrous substrate).

A fibrous substrate useful as a reservoir in an aerosol delivery devicecan be a woven or nonwoven material formed of a plurality of fibers orfilaments and can be formed of one or both of natural fibers andsynthetic fibers. For example, a fibrous substrate may comprise afiberglass material. In particular embodiments, a cellulose acetatematerial can be used. In other exemplary embodiments, a carbon materialcan be used.

One example embodiment of an aerosol delivery device 100 according tothe present disclosure is provided in FIG. 1. As seen in the cut-awayview illustrated therein, the aerosol delivery device 100 can comprise acontrol body 102 and a cartridge 104 that can be permanently ordetachably aligned in a functioning relationship. Engagement of thecontrol body 102 and the cartridge 104 can be press fit (asillustrated), threaded, interference fit, magnetic, or the like. Inparticular, connection components, such as further described herein maybe used. For example, the control body may include a coupler that isadapted to engage a connector on the cartridge.

In specific embodiments, one or both of the control body 102 and thecartridge 104 may be referred to as being disposable or as beingreusable. For example, the control body may have a replaceable batteryor a rechargeable battery and thus may be combined with any type ofrecharging technology, including connection to a typical electricaloutlet, connection to a car charger (i.e., cigarette lighterreceptacle), and connection to a computer, such as through a universalserial bus (USB) cable. For example, an adaptor including a USBconnector at one end and a control body connector at an opposing end isdisclosed in U.S. patent application Ser. No. 13/840,264 to Novak etal., filed Mar. 15, 2013, which is incorporated herein by reference inits entirety. Further, in some embodiments the cartridge may comprise asingle-use cartridge, as disclosed in U.S. patent application Ser. No.13/603,612 to Chang et al., filed Sep. 5, 2012, which is incorporatedherein by reference in its entirety.

As illustrated in FIG. 1, a control body 102 can be formed of a controlbody shell 101 that can include a control component 106 (e.g., amicrocontroller), a flow sensor 108, a battery 110, and an LED 112, andsuch components can be variably aligned. Further indicators (e.g., ahaptic feedback component, an audio feedback component, or the like) canbe included in addition to or as an alternative to the LED. A cartridge104 can be formed of a cartridge shell 103 enclosing the reservoir 144that is in fluid communication with a liquid transport element 136adapted to wick or otherwise transport an aerosol precursor compositionstored in the reservoir housing to a heater 134. Various embodiments ofmaterials configured to produce heat when electrical current is appliedtherethrough may be employed to form the resistive heating element 134.Example materials from which the wire coil may be formed include Kanthal(FeCrAl), Nichrome, Molybdenum disilicide (MoSi₂), molybdenum silicide(MoSi), Molybdenum disilicide doped with Aluminum (Mo(Si,Al)₂), graphiteand graphite-based materials (e.g., carbon-based foams and yarns) andceramics (e.g., positive or negative temperature coefficient ceramics).Exemplary embodiments of heating members useful in aerosol deliverydevices according to the present disclosure are further described below,and such heating members can be incorporated into devices such asillustrated in FIG. 1 as described herein.

An opening 128 may be present in the cartridge shell 103 (e.g., at themouthend) to allow for egress of formed aerosol from the cartridge 104.Such components are representative of the components that may be presentin a cartridge and are not intended to limit the scope of cartridgecomponents that are encompassed by the present disclosure.

The cartridge 104 also may include one or more electronic components150, which may include an integrated circuit, a memory component, asensor, or the like. The electronic component 150 may be adapted tocommunicate with the control component 106 and/or with an externaldevice by wired or wireless means. The electronic component 150 may bepositioned anywhere within the cartridge 104 or its base 140.

Although the control component 106 and the flow sensor 108 areillustrated separately, it is understood that the control component andthe flow sensor may be combined as an electronic circuit board with theair flow sensor attached directly thereto. Further, the electroniccircuit board may be positioned horizontally relative the illustrationof FIG. 1 in that the electronic circuit board can be lengthwiseparallel to the central axis of the control body. In some embodiments,the air flow sensor may comprise its own circuit board or other baseelement to which it can be attached. In some embodiments, a flexiblecircuit board may be utilized. A flexible circuit board may beconfigured into a variety of shapes, include substantially tubularshapes. In some embodiments, a flexible circuit board may be combinedwith, layered onto, or form part or all of a heater substrate as furtherdescribed below.

The control body 102 and the cartridge 104 may include componentsadapted to facilitate a fluid engagement therebetween. As illustrated inFIG. 1, the control body 102 can include a coupler 124 having a cavity125 therein. The cartridge 104 can include a base 140 adapted to engagethe coupler 124 and can include a projection 141 adapted to fit withinthe cavity 125. Such engagement can facilitate a stable connectionbetween the control body 102 and the cartridge 104 as well as establishan electrical connection between the battery 110 and control component106 in the control body and the heater 134 in the cartridge. Further,the control body shell 101 can include an air intake 118, which may be anotch in the shell where it connects to the coupler 124 that allows forpassage of ambient air around the coupler and into the shell where itthen passes through the cavity 125 of the coupler and into the cartridgethrough the projection 141.

A coupler and a base useful according to the present disclosure aredescribed in U.S. patent application Ser. No. 13/840,264 to Novak etal., filed Mar. 15, 2013, the disclosure of which is incorporated hereinby reference in its entirety. For example, a coupler as seen in FIG. 1may define an outer periphery 126 configured to mate with an innerperiphery 142 of the base 140. In one embodiment the inner periphery ofthe base may define a radius that is substantially equal to, or slightlygreater than, a radius of the outer periphery of the coupler. Further,the coupler 124 may define one or more protrusions 129 at the outerperiphery 126 configured to engage one or more recesses 178 defined atthe inner periphery of the base. However, various other embodiments ofstructures, shapes, and components may be employed to couple the base tothe coupler. In some embodiments the connection between the base 140 ofthe cartridge 104 and the coupler 124 of the control body 102 may besubstantially permanent, whereas in other embodiments the connectiontherebetween may be releasable such that, for example, the control bodymay be reused with one or more additional cartridges that may bedisposable and/or refillable.

The aerosol delivery device 100 may be substantially rod-like orsubstantially tubular shaped or substantially cylindrically shaped insome embodiments. In other embodiments, further shapes and dimensionsare encompassed—e.g., a rectangular or triangular cross-section,multifaceted shapes, or the like.

The reservoir 144 illustrated in FIG. 1 can be a container or can be afibrous reservoir, as presently described. For example, the reservoir144 can comprise one or more layers of nonwoven fibers substantiallyformed into the shape of a tube encircling the interior of the cartridgeshell 103, in this embodiment. An aerosol precursor composition can beretained in the reservoir 144. Liquid components, for example, can besorptively retained by the reservoir 144. The reservoir 144 can be influid connection with a liquid transport element 136. The liquidtransport element 136 can transport the aerosol precursor compositionstored in the reservoir 144 via capillary action to the heating element134 that is in the form of a metal wire coil in this embodiment. Assuch, the heating element 134 is in a heating arrangement with theliquid transport element 136. Exemplary embodiments of reservoirs andtransport elements useful in aerosol delivery devices according to thepresent disclosure are further described below, and such reservoirsand/or transport elements can be incorporated into devices such asillustrated in FIG. 1 as described herein. In particular, specificcombinations of heating members and transport elements as furtherdescribed below may be incorporated into devices such as illustrated inFIG. 1 as described herein.

In use, when a user draws on the article 100, airflow is detected by thesensor 108, the heating element 134 is activated, and the components forthe aerosol precursor composition are vaporized by the heating element134. Drawing upon the mouthend of the article 100 causes ambient air toenter the air intake 118 and pass through the cavity 125 in the coupler124 and the central opening in the projection 141 of the base 140. Inthe cartridge 104, the drawn air combines with the formed vapor to forman aerosol. The aerosol is whisked, aspirated, or otherwise drawn awayfrom the heating element 134 and out the mouth opening 128 in themouthend of the article 100.

The various components of an aerosol delivery device according to thepresent disclosure can be chosen from components described in the artand commercially available. Examples of batteries that can be usedaccording to the disclosure are described in U.S. Pat. App. Pub. No.2010/0028766 to Peckerar et al., the disclosure of which is incorporatedherein by reference in its entirety.

The aerosol delivery device can incorporate a sensor or detector forcontrol of supply of electric power to the heat generation element whenaerosol generation is desired (e.g., upon draw during use). As such, forexample, there is provided a manner or method for turning off the powersupply to the heat generation element when the aerosol delivery deviceis not be drawn upon during use, and for turning on the power supply toactuate or trigger the generation of heat by the heat generation elementduring draw. Additional representative types of sensing or detectionmechanisms, structure and configuration thereof, components thereof, andgeneral methods of operation thereof, are described in U.S. Pat. No.5,261,424 to Sprinkel, Jr.; U.S. Pat. No. 5,372,148 to McCafferty etal.; and PCT WO 2010/003480 by Flick; which are incorporated herein byreference.

The aerosol delivery device most preferably incorporates a controlmechanism for controlling the amount of electric power to the heatgeneration element during draw. Representative types of electroniccomponents, structure and configuration thereof, features thereof, andgeneral methods of operation thereof, are described in U.S. Pat. No.4,735,217 to Gerth et al.; U.S. Pat. No. 4,947,874 to Brooks et al.;U.S. Pat. No. 5,372,148 to McCafferty et al.; U.S. Pat. No. 6,040,560 toFleischhauer et al.; U.S. Pat. No. 7,040,314 to Nguyen et al. and U.S.Pat. No. 8,205,622 to Pan; U.S. Pat. Pub. Nos. 2009/0230117 to Fernandoet al. and 2014/0060554 to Collet et al.; and U.S. patent applicationSer. No. 13/837,542, filed Mar. 15, 2013, to Ampolini et al. and Ser.No. 14/209,191, filed Mar. 13, 2014, to Henry et al.; which areincorporated herein by reference.

Representative types of substrates, reservoirs or other components forsupporting the aerosol precursor are described in U.S. Pat. No.8,528,569 to Newton; and U.S. patent application Ser. No. 13/802,950,filed Mar. 15, 2013, to Chapman et al.; Ser. No. 14/011,192, filed Aug.28, 2013, to Davis et al. and Ser. No. 14/170,838, filed Feb. 3, 2014,to Bless et al.; which are incorporated herein by reference.Additionally, various wicking materials, and the configuration andoperation of those wicking materials within certain types of electroniccigarettes, are set forth in U.S. patent application Ser. No.13/754,324, filed Jan. 30, 2013, to Sears et al.; which is incorporatedherein by reference.

In some embodiments, the present disclosure provides a heating memberthat is useful for heating and vaporizing an aerosol precursorcomposition. The heating member can be particularly suited for providingconsistent, rapid vaporization of the aerosol precursor compositionwhile requiring minimal energy input.

An exemplary embodiment of a heating member 200 is illustrated in FIG.2. As seen therein, the heating member 200 comprises a heating element210 and a heater substrate 220. The heater substrate can comprise, forexample, a film, membrane, or the like underlying the heating element210. The heater substrate 220 can be formed of any material suitable forsupporting a heating element. In some embodiments, the heater substrate220 can be an electrically insulating material. The heater substrate 220likewise can be either heat insulating or heat conducting. The heatersubstrate 220 preferably is heat stable up to at least the temperatureachieved by the heating element. Polymeric materials in particular maybe used, for example, polyimides. The heater substrate 220 can comprisea material that can be provided in a sheet, film, or membrane form thatis substantially flattened and that is configurable into a variety ofshapes. The heater substrate 220 alternatively can be a molded orotherwise prefabricated shape. The heater substrate can be formed, forexample, from a ceramic. As illustrated in FIG. 2, the heater substrate220 is a thin film that is in a shape suitable for being configured intoa three-dimensional structure as otherwise described herein. The heatersubstrate 220 can vary in thickness. For example, heater substratethickness can be less than 2 mm, less than 1 mm, or less than 0.75 mm.In some embodiments, heater substrate thickness can be about 0.1 mm toabout 2 mm, about 0.2 mm to about 1.5 mm, or about 0.25 mm to about 1.25mm.

The heating element 210 can comprise a metal or like material asotherwise described herein suitable for providing resistive heating. Theheating element 210 can be combined with the heater substrate by anysuitable means, such as by etching techniques, printing techniques, oradhering techniques. For example, a metal ribbon can be laminated orotherwise affixed to the heater substrate. As a further example, anelectrically conductive ink can be printed on the surface of the heatersubstrate. A heating element comprising an electrically conductive inkcan be configured in a variety of patterns of varying complexity, andthe ink can be patterned in a manner that can improve aerosol formation.Printing of an electrically conductive ink on the heater substrate canimprove manufacturing in that fewer materials and/or fewer processingsteps may be required, and high throughput printing techniques can beutilized to rapidly prepare the heating member. Printed heating elementscan be textured.

The heating element 210 can include electrical terminals 211 a and 211b. The heating element can be substantially conformed to the heatersubstrate in that the heating element substantially bends, curves,flexes, or the like to substantially take on the shape of the heatersubstrate. For example, as further described herein, the heatersubstrate may be curved upon itself or similarly wrapped to form ahollow frustum or other truncated cone configuration. As the heatingelement is conformed to the heater substrate, the heating element isadapted to curve as the heater substrate is formed into the curvedshape. In some embodiments, the heating element can be characterized asbeing adhered to and/or in physical contact with the heater substratealong substantially the entire length of the heating element. In thisregard, the heating element can be applied to the heater substrate in avariety of configurations to achieve a desired heating profile, powerrequirement, heat output, or the like.

As illustrated in FIG. 2, the heating element 210 is conformed to theheater substrate 220 along a partial length of the heater substrate. Theportion of the heater substrate on which the heating element isconformed can vary. In some embodiments, the heating element can bepresent on the heater substrate along substantially the entire lengththereof. In the illustrated embodiment, the heater substrate 220includes a structural arm 221 that does not include the heating element.In practice, when the heater substrate is formed into the desired threedimensional shape, the structural arm 221 can overlap (or underlap) allor a section of the portion of the heater substrate to which the heatingelement is conformed.

In some embodiments, the heater substrate can be configured as anelongated structure having a first end of a first size and a second endof a greater size. Such elongated structure can be, for example, a cone,a truncated cone, a pyramid, a truncated pyramid, or other similargeometrical shape. In some embodiments, the heater substrate can includean interior passage therethrough. The heating member can have across-section that is substantially round, substantially square,substantially rectangular, substantially triangular, polygonal (e.g.,3-10 or 4-8 sides) or the like. A heating member in the form of atruncated cone can have a cone angle of up to about 60 degrees,particularly about 5 degrees to about 50 degrees.

As illustrated in the exemplary embodiment of FIG. 3, the heating member200 formed of a heating element 210 conformed to a heater substrate 220is configured as a frustum having a first end 230 of a first size and asecond end 240 of greater size. Although the illustrated structure is afrustum in that the first end 230 and second end 240 are substantiallyparallel, it is understood that there is no requirement that the firstand second ends be parallel. When included in an aerosol deliverydevice, the lesser sized end may be directed toward a mouthend of thedevice or the greater sized end may be directed to a mouthend of thedevice. The heating member 200 includes an interior passage 250therethrough from the first end 230 to the second end 240. Inembodiments wherein the heater substrate 220 is a film or membrane thatis folded, curved, or otherwise configured into the desired shape, it isunderstood that the interior passage 250 may have a shape thatsubstantially corresponds to the shape of the configured heatersubstrate. In other embodiments, the heater substrate may have a firstshape (e.g., an exterior shape), and the interior passage may have asecond, different shape. For example, the heater substrate can be amolded or 3-D printed element, and the interior passage can be providedin a defined shape of defined dimensions that can be designed tooptimize air flow through the device, optimize vapor formation, provideturbulent flow, or the like. As such, the substrate can be pre-formed inthe desired shape. The heating element in such embodiments can beconformed to an exterior surface of the molded or printed heatersubstrate and/or a surface defining the interior passage.

In some embodiments, the heater substrate of the heating member can beconfigured so that the heating element is in a heating arrangement atthe exterior of the heating member, for example on an outer surface ofthe heating member. In other embodiments, the heater substrate of theheating member can be configured so that the heating element is in aheating arrangement at an interior of the heating member, for examplewithin an interior passage of the heater substrate. With reference toFIG. 3, for example, the heater substrate 220 is wrapped (i.e., curvedaround) in a direction such that the heating element 210 is interior tothe heating member 200. In other words, the heating element 210 ispositioned to form a heating arrangement with an aerosol precursorcomposition that may be directed to the interior passage 250 of theheating member 200. It is understood that in other embodiments theheater substrate may be wrapped or curved in the opposing direction sothat the heating element is positioned to form a heating arrangementwith an aerosol precursor composition that may be directed to theexterior (particularly an outer surface) of the heating member.

In some embodiments, the heater substrate may be heat insulating, and aheating arrangement thus may be formed by directing an aerosol precursorcomposition to the side of the heater substrate on which the heatingelement is conformed. In other embodiments, the heater substrate may beheat conducting, and a heating arrangement thus may be formed bydirecting an aerosol precursor composition to the side of the heatersubstrate opposite to which the heating element is conformed. The sideof the heater substrate film or membrane on which the heating element isconformed can be referenced as the front side of the heater substrateand the opposing side of the heater substrate can be referenced as theback side of the heater substrate. For example, as seen in FIG. 4 (whichshows a cross-section through line 4-4 in FIG. 2), the heating element210 and electrical terminal 211 a are on the front side 220 a of theheater substrate 220, and the back side 220 b of the heater substratedoes not include a further element. If desired, a heating element may bepresent on both the front side and the back side of the heatersubstrate.

If desired, the heating member can comprise one or more films,membranes, or the like in addition to the heater substrate. For example,in the embodiment shown in FIG. 5, the heating member 200 comprises aheating element 210 conformed to a heater substrate 220 and includes aheater cover 260. The heater cover can be a film or membrane and can bemade of the same material or a different material than the heatersubstrate. The heater cover can be heat conducting or heat insulating.In some embodiments, the heater substrate can be heat insulating, andthe heater cover can be heat conducting. In other embodiments, theheater substrate can be heat conducting and the heater cover can be heatinsulating. The heating element can be defined as being sandwichedbetween two films or membranes of the same or different construction.The heater cover can have a substantially identical thickness to theheater substrate. Alternatively, the heater cover can have a thicknessthat is greater than the heater substrate thickness or lesser than theheater substrate thickness (as illustrated in FIG. 5). The heatingelement can be conformed to the heater cover or the heater cover can beapplied to the heater substrate without the requirement of being adheredor otherwise attached to the heating element. The heater substrate canhave a greater rigidity than the heater cover in some embodiments.Moreover, as the heating element is conformed to the heater substrate,the heater cover likewise can be conformed to the heater substrate suchthat the heater cover can take on the shape into which the heatersubstrate is configured. The heater cover can be present across theentirety of the surface of the heater substrate upon which the heatingelement is conformed. In some embodiments, the heater cover can bepresent only substantially in the area of the heater substrate to whichthe heating element is conformed. The heater cover can be characterizedas overlying the heating element.

The heater substrate and/or the heater cover (if present) can have atextured surface. Texturing can include any variety of shapes, includingstipples, dimples, channels, crosshatching, and the like. Texturing canbe useful to retain the aerosol precursor liquid on the surface of theheater substrate and/or heater cover and allow for more completevaporization. Texturing also can be useful to improve flow of theaerosol precursor liquid to the heating element, such as by providingcapillary flow paths across the surface of the heater substrate and/orheater cover. Texturing may substantially conform to the shape of theheating element such that aerosol precursor liquid on the surface of theheater substrate and/or heater cover may be directed (such as bycapillary action) across the surface to the precise location of theheating element.

An aerosol delivery device according to embodiments of the presentdisclosure can comprise a porous transport element that is configuredfor passage of an aerosol precursor composition along a length thereof.The porous transport element can be formed of any material suitable forproviding movement of a liquid, such as via capillary action. The poroustransport element can be in fluid communication with a separatereservoir that is configured for storage of a liquid aerosol precursorcomposition. In some embodiments, the porous transport element can be influid communication with a reservoir such that the transport element andthe reservoir are in physical contact. In other embodiments, the poroustransport element can be sufficiently dimensioned so as to absorptivelystore the liquid aerosol precursor composition and thus function both asa reservoir and a wick.

The porous transport element can be a fibrous material, such asotherwise described herein, for example a carbon fiber material, afiberglass material, or the like. The porous transport element can besubstantially elongated so as to have at least a first end, and thetransport element can be configured so that the first end thereof is ina heating arrangement with the heating member.

In some embodiments, the porous transport element can be substantiallyin the form of a fibrous mat. Such fibrous mat can be formed of a singlelayer or can be formed of a plurality of layers. In particular, thetransport element can be structured so that the first end of the fibrousmat comprises fewer layers than the remainder of the fibrous mat. Forexample, the transport element can comprise two or more layers of afibrous material or different fibrous materials annularly aligned. Insome embodiments, the transport element can comprise a substantiallytubular fibrous mat with a free first end and with a second end that isat least partially surrounded by a reservoir, which can comprise one ormore layers of a fibrous material.

In embodiments comprising a plurality of layers, the layers can comprisedifferent materials exhibiting one or more different properties. Forexample, an inner layer may exhibit greater wicking than the outer layerso as to promote movement of liquid from the outer layer (which mayfunction substantially as a reservoir layer) to the inner layer (whichmay function substantially as a wick to transport liquid from thereservoir layer to the heating member).

An exemplary embodiment of a transport element 136 is shown in FIG. 6.In the illustrated embodiment, the transport element 136 comprises afirst end 681 and a second end 682. At the first end 681, the transportelement 136 comprises a single layer fibrous mat 611. At the second end682, the transport element 136 comprises a multi-layer fibrous mat 613.As illustrated (see FIG. 6 and FIG. 7), the single layer fibrous mat 611extends into the multi-layer fibrous mat 613 and thus may be consideredto form a layer of the multi-layer fibrous mat. The multi-layer fibrousmat 613 may comprise fibers that are different from the fibers formingthe single layer fibrous mat 611. Alternatively, the multi-layer fibrousmat 613 can comprise a plurality of layers of the same fibrous materialforming the single layer fibrous mat 611. Because the multi-layerfibrous mat 613 contains a greater bulk of material, the multi-layerfibrous mat may function as a reservoir. Alternatively, a separatereservoir may be combined with the transport element 136.

The transport element 136 of FIG. 6 is further illustrated in thecross-section through line 7-7 shown in FIG. 7. As illustrated, themulti-layer fibrous mat 613 comprises two layers 613 a and 613 b withthe single layer fibrous mat 611 positioned interior thereto. Theplurality of layers thus can be concentric layers. As seen in FIG. 7,the transport element further can comprise a central passage 660therethrough. Particularly, the central passage can extend along theentire length of the transport element from the first end to the secondend. In some embodiments, one or both ends of the transport element maybe closed.

A heating member and a porous transport element can be combined in avariety of manners in an aerosol delivery device according to thepresent disclosure. For example, in the embodiment illustrated in FIG.8, an aerosol delivery device 800 comprises a shell 803 and a mouthpiece805 with an opening 828 therein for passage of formed aerosol from thedevice. The shell 803 can define a single unit that can further includecontrol components and power components, such as illustrated in relationto the control body 102 of FIG. 1. The shell 803 alternatively candefine a cartridge (such as cartridge 104 in FIG. 1) having a controlbody attachment end 806 that can be configured for attachment to acontrol body and that can include attachment elements, such as describedin relation to FIG. 1.

The aerosol delivery device 800 in the embodiment of FIG. 8 furthercomprises a heating member 200 formed of a heating element 210 conformedto a heater substrate 220 configured as a truncated cone having a firstend 230 of a first size and a second end 240 of greater size. Theheating member 200 further includes a heater cover 260. The heatersubstrate 220 and the heater cover 260 are each configured as thin filmsin the illustrated embodiment such that the heating element 210 issubstantially sandwiched between the heater substrate and the heatercover. As illustrated, the heater substrate 220 can be heat insulating,and the heater cover 260 can be heat conducting.

In FIG. 8, the heating member 200 includes an interior passage 250through the truncated cone formed by the heater substrate 220, theheating element 210, and the heater cover 260. The aerosol deliverydevice 800 also includes a porous transport element 836 that comprises afirst end 881 and a second end 882. The porous transport element 836 isformed of a plurality of layers of a fibrous mat such that a singlelayer fibrous mat 811 forms the first end 881 of the transport elementand multi-layer fibrous mat 813 forms the second end 882 of thetransport element. The multi-layer fibrous mat 813 can comprise aportion of the single layer fibrous mat 811 surrounded by at least asecond layer of the fibrous mat. In the partial section of FIG. 8, thegreater fiber density of the multi-layer fibrous mat 813 cause thesingle layer fibrous mat 811 to blend therewith and become visuallyobscured. The first end 881 of the porous transport element 836 ispositioned within the interior passage 250 of the heating member 200 soas to be in a heating arrangement with the heating element 210. Theporous transport element 836 has an aerosol precursor composition storedtherein, particularly within the multi-layer fibrous mat 813. As theheating element 210 is heated, the aerosol precursor composition in thesingle layer mat 811 at the first end 881 of the transport element 836is vaporized to form a vapor 899 that mixes with air (see dotted line A)to form an aerosol 10 in the cavity 897 within the shell 803. The vaporforms within the central passage 860 (illustrated by the dashed lines)through the transport element. Thus, in some embodiments, the aerosoldelivery device can be defined as comprising an airflow path (flow ofair A in FIG. 8) entering the lesser sized first end 881 of thetruncated cone formed by the heater substrate 220, passing through aninterior passage (e.g., central passage 860 in FIG. 8 or central pathway855 in FIG. 9), and exiting at the greater sized second end 882 of thetruncated cone. The nature of the heater substrate can be particularlybeneficial in providing for turbulent airflow that can better entrainformed vapor. The heater substrate alone or in combination with one ormore further elements of the aerosol delivery device can be configuredto cause air passing therethrough to substantially form a vortex or canbe configured to substantially cause laminar air flow.

In some embodiments, further elements may be present. For example, theembodiment illustrated in FIG. 9 is substantially identical to theembodiment of FIG. 8 but includes further structural elements. Inparticular, the aerosol delivery device 800 of FIG. 9 comprises asupport member 845 passing centrally longitudinally through the poroustransport element 836 substantially from the first end 881 thereof tothe second end 882 thereof. The support member 845 can be tapered at oneend thereof and can extend beyond the first end 881 of the transportelement 836 (as well as beyond the second end 882 of the transportmember). The support member 845 can include a central pathway 855extending longitudinally therethrough or having an otherwise definedpathway therethrough. In some embodiments, the support member 845 cancomprise a flow diverter 854 positioned within at least a portion of thecentral pathway 855. The flow diverter 854 can be positioned so that airentering the central pathway 855 is diverted through one or more airoutlets 853 to the vaporization zone 898 between the heating member 200and the support member 845 where vapor is formed by heating of theaerosol precursor composition in the porous transport element 836 by theheating element 210. Aerosol formed by the vapor mixing with air thencan pass back into the central pathway 855 through one or more aerosoloutlets 852 positioned downstream from the one or more air inlets 853.The one or more air inlets 853 and the one or more aerosol outlets 852can be formed in the wall of the support member 845 and can be one ormore apertures, a plurality of perforations, or the like. The flowdiverter 854 can comprise a flange 854 a that can be substantially equalto the inner diameter of the shell 803 or can be shorter, and the flangecan include one or more flange apertures 854 b in alignment with thecentral pathway 855 to permit flow of air and aerosol therethrough (asshown by the dashed arrow). The support member 845 can include a radialextension 845 a that can be configured to substantially block airflowaround the exterior of the support member downstream from the aerosoloutlets 852, particularly preventing passage of formed aerosol from thevaporization zone 898 around the exterior of the support member. Theaerosol delivery device 800 further can comprise a heater frame 847 thatcan substantially surround the heating member 200 and provide structuralrigidity thereto. The support member 845 and the heater frame 847 cancomprise any material suitable for use in an aerosol delivery device,such as thermoplastics, metals, ceramics, and the like. The heater frame847 can have an open free end. The heater frame 847 can be configured tosubstantially encapsulate the heating member 200 and can have minimizedcontact with the heating member. For example, the heater frame 847 canbe configured to be in physical contact with one or both of the firstend 230 and the second end 240 of the heating member 200. Such contactcan be directly at the respective end or can be in the area of therespective end. The contacts between the heater frame 847 and theheating member 200 can define a void space between the heater frame andthe heating member. Such configuration can be beneficial to minimizeheat loss from the heating member 200 to other components of the aerosoldelivery device 800 other than the porous transport element 836.Combinations of certain elements described herein can be configured asan atomizer suitable for use with a variety of aerosol delivery devices.For example, a heating member as described herein can be combined with awick to form an atomizer. The heating member can particularly becombined with a porous transport element as described herein to form anatomizer. In some embodiments, an atomizer can comprise a heatingmember, a porous transport element, and one or both of a heater frameand a support member. An atomizer also can comprise electrical contacts.

In further embodiments, the heating member and the porous transportelement can be combined differently. For example, in the embodimentillustrated in FIG. 10, the first end 881 of the porous transportelement 836 can be positioned so as to at least partially surround thefirst end 230 of the truncated cone formed by the heater substrate 220and thus be in a heating arrangement with the heating element 210 of theheating member 200. In such embodiments, a support member (845 in FIG.9) or a heater frame (847 in FIG. 9) or both a support member and aheater frame can be present. When present, the support member may extendfully or partially through the transport element longitudinally and mayextend fully or partially through the heating member. In embodimentsexemplified by FIG. 10, the aerosol delivery device 800 can comprise anairflow path 856 that is exterior to the heating element and that passesaround the truncated cone formed by the heater substrate 220. Theairflow path 856 can pass around the heating member 200 from the firstend 230 thereof to the greater sized second end 240 thereof. Vapor thuscan be formed outside or exterior to the heating member 200 (as opposedto being formed within an interior passage through the heating member).Formed vapor can be entrained in the air through the airflow path andexit the aerosol delivery device through the opening 828 in themouthpiece 805.

In some embodiments, the present disclosure further provides methods forforming an aerosol delivery device substantially as described herein.The methods can comprise a variety of steps that are not restricted byorder of implementation unless otherwise indicated. In some embodiments,a method of forming an aerosol delivery device can comprise configuringa heating member as described herein and positioning the heating memberwithin a shell. Particularly, the heating member can be configured as atruncated cone having a first end of a first size and a second end ofgreater size, and the so configured heating member can be insertedwithin the shell.

In particular embodiments, methods according to the present disclosurecan comprise providing a porous transport element configured for passageof an aerosol precursor composition along a length thereof, the poroustransport element having a first end and a second opposing end, andconfiguring the first end thereof in a heating arrangement with theheating member. The methods also can comprise contacting the second endof the porous transport element with the aerosol precursor composition.The truncated cone can include a central passage therethrough, andconfiguring the first end of the porous transport element in a heatingarrangement with the heating member can comprise inserting the first endof the porous transport element into the central passage at the second,greater sized end of the heating member. In some embodiments, the firstend of the porous transport element can comprise a central openingtherein, and configuring the first end of the porous transport elementin a heating arrangement with the heating member can comprise insertingthe first, lesser sized end of the heating member into the centralopening in the first end of the porous transport element.

The aerosol precursor, or vapor precursor composition, useful in anaerosol delivery device as described herein can vary. Most preferably,the aerosol precursor is composed of a combination or mixture of variousingredients or components. The selection of the particular aerosolprecursor components, and the relative amounts of those components used,may be altered in order to control the overall chemical composition ofthe mainstream aerosol produced by the aerosol generating piece. Ofparticular interest are aerosol precursors that can be characterized asbeing generally liquid in nature. For example, representative generallyliquid aerosol precursors may have the form of liquid solutions, viscousgels, mixtures of miscible components, or liquids incorporatingsuspended or dispersed components. Typical aerosol precursors arecapable of being vaporized upon exposure to heat under those conditionsthat are experienced during use of the aerosol generating pieces thatare characteristic of the current disclosure; and hence are capable ofyielding vapors and aerosols that are capable of being inhaled.

For aerosol delivery systems that are characterized as electroniccigarettes, the aerosol precursor most preferably incorporates tobaccoor components derived from tobacco. In one regard, the tobacco may beprovided as parts or pieces of tobacco, such as finely ground, milled orpowdered tobacco lamina. In another regard, the tobacco may be providedin the form of an extract, such as a spray dried extract thatincorporates many of the water soluble components of tobacco.Alternatively, tobacco extracts may have the form of relatively highnicotine content extracts, which extracts also incorporate minor amountsof other extracted components derived from tobacco. In another regard,components derived from tobacco may be provided in a relatively pureform, such as certain flavoring agents that are derived from tobacco. Inone regard, a component that is derived from tobacco, and that may beemployed in a highly purified or essentially pure form, is nicotine(e.g., pharmaceutical grade nicotine).

The aerosol precursor may incorporate a so-called “aerosol formingmaterials.” Such materials have the ability to yield visible aerosolswhen vaporized upon exposure to heat under those conditions experiencedduring normal use of aerosol generating pieces that are characteristicof the current disclosure. Such aerosol forming materials includevarious polyols or polyhydric alcohols (e.g., glycerin, propyleneglycol, and mixtures thereof). Many embodiments of the presentdisclosure incorporate aerosol precursor components that can becharacterized as water, moisture or aqueous liquid. During conditions ofnormal use of certain aerosol generating pieces, the water incorporatedwithin those pieces can vaporize to yield a component of the generatedaerosol. As such, for purposes of the current disclosure, water that ispresent within the aerosol precursor may be considered to be an aerosolforming material.

It is possible to employ a wide variety of optional flavoring agents ormaterials that alter the sensory character or nature of the drawnmainstream aerosol generated by the aerosol delivery system of thepresent disclosure. For example, such optional flavoring agents may beused within the aerosol precursor to alter the flavor, aroma andorganoleptic properties of the aerosol. Certain flavoring agents may beprovided from sources other than tobacco. Exemplary flavoring agents maybe natural or artificial in nature, and may be employed as concentratesor flavor packages.

Exemplary flavoring agents include vanillin, ethyl vanillin, cream, tea,coffee, fruit (e.g., apple, cherry, strawberry, peach and citrusflavors, including lime and lemon), maple, menthol, mint, peppermint,spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger,honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa,licorice, and flavorings and flavor packages of the type and charactertraditionally used for the flavoring of cigarette, cigar and pipetobaccos. Syrups, such as high fructose corn syrup, also can beemployed. Certain flavoring agents may be incorporated within aerosolforming materials prior to formulation of a final aerosol precursormixture (e.g., certain water soluble flavoring agents can beincorporated within water, menthol can be incorporated within propyleneglycol, and certain complex flavor packages can be incorporated withinpropylene glycol).

Aerosol precursors also may include ingredients that exhibit acidic orbasic characteristics (e.g., organic acids, ammonium salts or organicamines). For example, certain organic acids (e.g., levulinic acid,succinic acid, lactic acid, and pyruvic acid) may be included in anaerosol precursor formulation incorporating nicotine, preferably inamounts up to being equimolar (based on total organic acid content) withthe nicotine. For example, the aerosol precursor may include about 0.1to about 0.5 moles of levulinic acid per one mole of nicotine, about 0.1to about 0.5 moles of succinic acid per one mole of nicotine, about 0.1to about 0.5 moles of lactic acid per one mole of nicotine, about 0.1 toabout 0.5 moles of pyruvic acid per one mole of nicotine, or variouspermutations and combinations thereof, up to a concentration wherein thetotal amount of organic acid present is equimolar to the total amount ofnicotine present in the aerosol precursor.

As one non-limiting example, a representative aerosol precursor can havethe form of a mixture of about 70% to about 90% glycerin, often about75% to about 85% glycerin; about 5% to about 20% water, often about 10%to about 15% water; about 1% to about 10% propylene glycol, often about4% to about 8% propylene glycol; about 0.1% to about 6% nicotine, oftenabout 1.5% to about 5% nicotine; and optional flavoring agent in anamount of up to about 6%, often about 0.1% to about 5% flavoring agent;on a weight basis. For example, a representative aerosol precursor mayhave the form of a formulation incorporating greater than about 76%glycerin, about 14% water, about 7% propylene glycol, about 1% to about2% nicotine, and less than about 1% optional flavoring agent, on aweight basis. For example, a representative aerosol precursor may havethe form of a formulation incorporating greater than about 75% glycerin,about 14% water, about 7% propylene glycol, about 2.5% nicotine, andless than about 1% optional flavoring agent. For example, arepresentative aerosol precursor may have the form of a formulationincorporating greater than about 75% glycerin, about 5% water, about 8%propylene glycol, about 6% nicotine, and less than about 6% optionalflavoring agent, on a weight basis.

As another non-limiting example, a representative aerosol precursor canhave the form of a mixture of about 40% to about 70% glycerin, oftenabout 50% to about 65% glycerin; about 5% to about 20% water, oftenabout 10% to about 15% water; about 20% to about 50% propylene glycol,often about 25% to about 45% propylene glycol; about 0.1% to about 6%nicotine, often about 1.5% to about 5% nicotine; about 0.5% to about 3%,often about 1.5% to about 2% menthol; and optional additional flavoringagent in an amount of up to about 6%, often about 0.1% to about 5%flavoring agent; on a weight basis. For example, a representativeaerosol precursor may have the form of a formulation incorporating about50% glycerin, about 11% water, about 28% propylene glycol, about 5%nicotine, about 2% menthol, and about 4% other flavoring agent, on aweight basis.

Representative types of aerosol precursor components and formulationsalso are set forth and characterized in U.S. Pat. No. 7,217,320 toRobinson et al. and U.S. Pat. Pub. Nos. 2013/0008457 to Zheng et al.;2013/0213417 to Chong et al. and 2014/0060554 to Collett et al., thedisclosures of which are incorporated herein by reference. Other aerosolprecursors that may be employed include the aerosol precursors that havebeen incorporated in the VUSE® product by R. J. Reynolds Vapor Company,the BLU™ product by Lorillard Technologies, the MISTIC MENTHOL productby Mistic Ecigs, and the VYPE product by CN Creative Ltd. Also desirableare the so-called “smoke juices” for electronic cigarettes that havebeen available from Johnson Creek Enterprises LLC.

The amount of aerosol precursor that is incorporated within the aerosoldelivery system is such that the aerosol generating piece providesacceptable sensory and desirable performance characteristics. Forexample, it is highly preferred that sufficient amounts of aerosolforming material (e.g., glycerin and/or propylene glycol), be employedin order to provide for the generation of a visible mainstream aerosolthat in many regards resembles the appearance of tobacco smoke. Theamount of aerosol precursor within the aerosol generating system may bedependent upon factors such as the number of puffs desired per aerosolgenerating piece. Typically, the amount of aerosol precursorincorporated within the aerosol delivery system, and particularly withinthe aerosol generating piece, is less than about 2 g, generally lessthan about 1.5 g, often less than about 1 g and frequently less thanabout 0.5 g.

Additional representative types of components that yield visual cues orindicators, such as light emitting diode (LED) components, and theconfigurations and uses thereof, are described in U.S. Pat. No.5,154,192 to Sprinkel et al.; U.S. Pat. No. 8,499,766 to Newton and U.S.Pat. No. 8,539,959 to Scatterday; and U.S. patent application Ser. No.14/173,266, filed Feb. 5, 2014, to Sears et al.; which are incorporatedherein by reference.

Yet other features, controls or components that can be incorporated intoaerosol delivery systems of the present disclosure are described in U.S.Pat. No. 5,967,148 to Harris et al.; U.S. Pat. No. 5,934,289 to Watkinset al.; U.S. Pat. No. 5,954,979 to Counts et al.; U.S. Pat. No.6,040,560 to Fleischhauer et al.; U.S. Pat. No. 8,365,742 to Hon; U.S.Pat. No. 8,402,976 to Fernando et al.; U.S. Pat. App. Pub. Nos.2010/0163063 by Fernando et al.; 2013/0192623 to Tucker et al.;2013/0298905 to Leven et al.; 2013/0180553 to Kim et al. and2014/0000638 to Sebastian et al.; and U.S. patent application Ser. No.13/840,264, filed Mar. 15, 2013, to Novak et al. and Ser. No.13/841,233, filed Mar. 15, 2013, to DePiano et al.; which areincorporated herein by reference.

The foregoing description of use of the article can be applied to thevarious embodiments described herein through minor modifications, whichcan be apparent to the person of skill in the art in light of thefurther disclosure provided herein. The above description of use,however, is not intended to limit the use of the article but is providedto comply with all necessary requirements of disclosure of the presentdisclosure. Any of the elements shown in the article illustrated in FIG.1 or as otherwise described above may be included in an aerosol deliverydevice according to the present disclosure.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

That which is claimed is:
 1. A method of forming an aerosol deliverydevice comprising: providing a shell; providing a heating member formedof a heating element conformed to a substrate; configuring the heatingmember as a truncated cone having a first end of a first size and asecond end of greater size; and inserting the heating member within theshell.
 2. The method according to claim 1, further comprising providinga porous transport element configured for passage of an aerosolprecursor composition along a length thereof, the porous transportelement having a first end and a second opposing end, and configuringthe first end thereof in a heating arrangement with the heating member.3. The method according to claim 2, further comprising contacting thesecond end of the porous transport element with the aerosol precursorcomposition.
 4. The method according to claim 2, wherein the truncatedcone includes a central passage therethrough, and wherein configuringthe first end of the porous transport element in a heating arrangementwith the heating member comprises inserting the first end of the poroustransport element into the central passage at the second, greater sizedend of the heating member.
 5. The method according to claim 2, whereinthe first end of the porous transport element comprises a centralopening therein, and wherein configuring the first end of the poroustransport element in a heating arrangement with the heating membercomprises inserting the first, lesser sized end of the heating memberinto the central opening in the first end of the porous transportelement.
 6. The method according to claim 1, wherein providing theheating member comprises forming the heating member on the substrate byprinting an electrically conductive ink thereon.
 7. A method of formingan aerosol delivery device comprising: providing a shell; providing aheating member formed of a heating element conformed to a substrate,wherein providing the heating member comprises forming the heatingmember on the substrate by printing an electrically conductive inkthereon; configuring the heating member as a truncated cone having afirst end of a first size and a second end of greater size, wherein thetruncated cone includes a central passage therethrough; providing aporous transport element configured for passage of an aerosol precursorcomposition along a length thereof, the porous transport element havinga first end and a second opposing end; configuring the first end theporous transport element in a heating arrangement with the heatingmember, wherein configuring the first end of the porous transportelement in a heating arrangement with the heating member comprisesinserting the first end of the porous transport element into the centralpassage at the second, greater sized end of the heating member; andinserting the heating member within the shell.